ELECTRICAL SYSTEM
7-1
ELECTRICAL SYSTEM
CONTENTS 7- 3 CAUTIONS IN SERVICING 7- 3 COUPLER 7- 3 CLAMP 7- 3 FUSE SEMI-CONDUCTOR EQUIPPED PART 7- 3 7- 4 BATTERY CONNECTING THE BATTERY 7- 4 7- 4 WIRING PROCEDURE USING THE MULTI CIRCUIT TESTER 7- 4 LOCATION OF ELECTRICAL COMPONENTS 7- 5 7- 7 CHARGING SYSTEM 7- 7 TROUBLE SHOOTING 7- 9 INSPECTION STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK 7-12 SYSTEM 7-12 TROUBLE SHOOTING STARTER MOTOR REMOVAL AND DISASSEMBLY 7-13 7-14 STARTER MOTOR INSPECTION 7-15 STARTER MOTOR REASSEMBLY 7-16 STARTER RELAY INSPECTION SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS 7-17 INSPECTION 7-20 IGNITION SYSTEM 7-20 TROUBLESHOOTING 7-22 INSPECTION 7-25 COMBINATION METER 7-25 REMOVAL 7-26 PARTS NAME 7-26 OPERATING PROCEDURE 7-28 ENGINE COOLANT TEMPERATURE METER AND INDICATOR 7-31 LAMPS 7-31 HEADLIGHT AND POSITION LIGHT BRAKE LIGHT/TAILLIGHT, TURN SIGNAL LIGHT AND LICENCE PLATE LIGHT RELAYS TURN SIGNAL/SIDE-STAND RELAY STARTER RELAY FUEL PUMP RELA Y SWITCHES
7-32 7-33 7-33 7-33 7--33 7-34
7
7-2
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONTENTS BATTERY SPECIFICATIONS INITIAL CHARGING SERVICING RECHARGING OPERATION
7-36 7-36 7-36 7-37 7-38
ELECTRICAL SYSTEM 7- 3
CAUTIONS IN SERVICING COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • Inspect each terminal on the coupler for being loose or bent . • Inspect each terminal for corrosion and contamination .
CLAMP • Clamp the wire harness at such positions as indicated in "WIRE HARNESS ROUTING" . (C"-78-14) • Bend the clamp properly so that the wire harness is clamped securely . • In clamping the wire harness, use care not to allow it to hang down . • Do not use wire or any other substitute for the band type clamp .
FUSE • When a fuse blows, always investigate the cause, correct it and then replace the fuse . • Do not use a fuse of a different capacity . • Do not use wire or any other substitute for the fuse .
SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part with a semi-conductor built in such as a ECM . • When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part .
7-4 ELECTRICAL SYSTEM
BATTERY • The MF battery used in this motorcycle does not require maintenance (e .g ., electrolyte level inspection, distilled water replenishment) . • During normal charging, no hydrogen gas is produced . However, if the battery is overcharged, hydrogen gas may be produced . Therefore, be sure there are no fire or spark sources (e .g ., short circuit) nearby when charging the battery . • Be sure to recharge the battery in a well-ventilated and open area . • Note that the charging system for the MF battery is different from that of a conventional battery . Do not replace the MF battery with a conventional battery .
CONNECTING THE BATTERY • When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first . • When connecting the battery lead wires, be sure to connect the OO battery lead wire first . • If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • After connecting the battery, apply a light coat of grease to the battery terminals . • Install the cover over the O battery terminal .
WIRING PROCEDURE • Properly route the wire harness according to the "WIRE HARNESS ROUTING" section . (CJ8-14)
USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester O and e probes . Improper use can cause damage to the motorcycle and tester . • If the voltage and current values are not known, begin measuring in the highest range . • When measuring the resistance, make sure that no voltage is applied . If voltage is applied, the tester will be damaged . • After using the tester, be sure to turn the switch to the OFF position . CAUTION Before using the multi circuit tester, read its instruction manual .
ELECTRICAL SYSTEM 7-5
LOCATION OF ELECTRICAL COMPONENTS
~ 40
• Fuel pump (C14-68) 02 CMP sensor (C'4-92) ~3 IAP sensor (=4-91) • Ignition coil (No . 1) 05 Horn
® TO sensor (=4-93) 4-93) 07 Gear position switch • Starter motor • Oil pressure switch 1o ECT sensor (f- 4-93)
7-6 ELECTRICAL SYSTEM
90 Cooling fan thermo-switch ( F-75-9) O Battery 10 ECM (Engine Control Module) • Cooling fan (r-75-8) Cooling fan motor switch coupler (=5-8) 5-8) 11 Fuel pump relay • • Fuel injector (r--74-86) 0 AP sensor (=4-93) 4-93) ~5 TP sensor (=4-91) 13 Starter relay 14 Side-stand/turn signal relay • STP sensor ( f" 74-91) Secondary throttle valve actuator (=4-51) 4-51) 15 Fuse box • 16 Mode selection switch coupler • IAT sensor (r--74-92)
17 Ignition coil (No . 2) 18 Regulator/rectifier 19 Generator 20 Speedometer sensor 21 CKP sensor 22 Side stand switch
ELECTRICAL SYSTEM 7-7
j
CHARGING
SYSTEM
Regulator/rectifier
4)
Ig .switch
Generator
I I I
I I is
I I
I a
4)
m
I N
I
I
~
TROUBLE
.,
SCR
SHOOTING
Battery runs down quickly . Step 1 1) Check accessories which use excessive amounts of electricity . Are accessories being installed? YES NO
Remove accessories . Go to Step 2 .
Step 2 1) Check the battery for current leaks . (=7-9) Is the battery for current leaks OK? YES NO
40
Go to Step 3 . • Short circuit of wire harness • Faulty electrical equipment
Step 3 1) Measure the charging voltage between the battery terminals . (11r7-9) Is the battery charging of voltage OK? YES NO
• Faulty battery • Abnormal driving condition Go to Step 4 .
l m
0 J
7-8 ELECTRICAL SYSTEM
Step 4 1) Measure the resistance of the generator coil . (=7-1 0) Is the resistance of generator coil OK? YES NO
Go to Step 5 . Faulty generator coil or disconnected lead ~^ .iros
Step 5 1) Measure the generator no-load voltage . (C_r7-10) Is the generator no-load voltage OK? YES NO
Go to Step 6 . Faulty generator
Step 6 1) Inspect the regulator/rectifier . ( I"77-11) Is the regulator/rectifier OK? YES NO
Go to Step 7 . Faulty regulator/rectifier
Step 7 1) Inspect the wirings . Are the wirings OK? YES NO
Faulty battery • Short circuit of wire harness • Poor contact of couplers
Battery overcharge • Faulty regulator/rectifier • Faulty battery • Poor contact of generator lead wire coupler
ELECTRICAL SYSTEM
INSPECTION j
BATTERY CURRENT LEAKAGE • Remove the front seat . (=6-7)
• Turn the ignition switch to the OFF position . • Disconnect the O battery lead wire . Measure the current between the O battery terminal and the O battery lead wire using the multi circuit tester . If the reading exceeds the specified value, leakage is evident . Battery current (leak) : Under 3 mA 09900-25008 : Multi circuit tester set ~j Tester knob indication : Current (-, 20 mA) CAUTION * Because the current leak might be large, turn the tester to high range first to avoid tester damage . * Do not turn the ignition switch to the "ON" position when measuring current . When checking to find the excessive current leakage, remove the couplers and connectors, one by one, checking each part .
REGULATED VOLTAGE • Remove the front seat . (r'6-7)
• Start the engine and keep it running at 5 000 r/min with the dimmer switch turned HI position . Measure the DC voltage between the O and O battery terminals using the multi circuit tester . If the voltage is not within the specified value, inspect the generator and regulator/rectifier . (r--r7-1 1) NOTE : When making this test, be sure that the battery is in fullycharged condition . Charging output (Regulated voltage) : 14 .0 - 15 .5 V at 5 000 r/m i n ..
09900-25008 : Multi circuit tester set Tester knob indication : Voltage (-)
7-9
7 .10 ELECTRICAL SYSTEM
GENERATOR COIL RESISTANCE • Remove the front seat . ( F-76-7) • Disconnect the generator coupler
D.
Measure the resistance among the three lead wires . If the resistance is not specified value, replace the stator with a new one . Also, check that the generator core is insulated . ['
Generator coil resistance : 0 .2 - 0 .7 S2 (Yellow - Yellow) - S (Yellow - Ground) 09900-25008 : Multi circuit tester set
ZJ Tester knob indication : Resistance (S2) NOTE: When making above test, it is not necessary to remove the generator.
GENERATOR NO-LOAD PERFORMANCE • Disconnect the generator coupler . (Crabove) • Don't disconnect the crankshaft position sensor coupler . • Start the engine and keep it running at 5 000 r/min . Using the multi circuit tester, measure the voltage among the three lead wires . If the tester reads under the specified value, replace the generator with a new one . Generator no-load performance : 75 V and more at 5 000 r/min (When engine is cold) 09900-25008 : Multi circuit tester set Tester knob indication : Voltage (-)
A A
A
ELECTRICAL SYSTEM
I
REGULATOR/RECTIFIER • Disconnect the couplers and remove the regulator/rectifier .
4)
tester as indicated in the table below . If the voltage is not within
Measure the voltage among the terminals using the multi circuit
the specified value, replace the regulator/rectifier with a new one . 09900-25008 : Multi circuit tester set ~$ Tester knob indication : Diode test (-W) Unit : V O
B/R
g
B/R
~'
0
a OI
Probe of tester to : 131
0 .4 - 0 .7
131
*
B2
*
B2
B3
B/W
0 .4 - 0 .7 0 .4 - 0 .7 0 .5 - 1 .2 *
*
*
0 .4-0 .7
*
0 .4-0 .7
B3
0 .4 - 0 .7
B/W
B : Black, B/R : Black with Red trancer * More than 1 .4 V (tester's battery voltage)
NOTE: If the tester reads under 1 .4 V when the tester probes are not connected, replace the battery of multi circuit tester .
7-11
7-12 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM
Engine stop switch 0
0
Starter motor
A rr
Ignition switch Fuse (30 A)
To ECM and ignition coil Y/G
ro m
Starter relay
B/Y Clutch lever position switch
Starter button
B/W I
W
TROUBLE SHOOTING Starter motor will not run . Step 1
1) The transmission is in neutral . Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the "RUN" position . 2) Listen for a click from the starter relay when the starter button is pushed . Is a click sound heard? YES NO
Go to Step 2 . Go to Step 3 .
Step 2
1) Check if the starter motor runs when its terminal is connected to the "wire" because a large amount of current flows .) Does the starter motor run? YES NO
• Faulty starter relay • Loose or disconnected starter motor lead wire Faulty starter motor
O battery terminal . (Do not use thin
In
J
ELECTRICAL SYSTEM
Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G
O+
and B/Y
O)
7- 1 3
when the
starter button is pushed . Is the voltage OK? YES
Go to Step 4 .
NO
• • • • • • • •
Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty gear position switch Faulty turn signal/side-stand relay Faulty starter button Poor contact of connector Open circuit in wire harness
Step 4 1) Check the starter relay . (F-t 7-1 6) Is the starter relay OK? YES
Poor contact of the starter relay
NO
Faulty starter relay
NOTE : The starter motor runs when the transmission is in neutral with the side-stand up or down, but does not run when the transmission is in any position other than neutral with the side-stand down . 2) Check the side-stand switch . (CIT7-17) Is the side-stand switch OK? YES
• Open circuit in wire harness • Poor contact of connector
NO
Faulty side-stand switch
Engine does not turn though the starter motor runs .
• Faulty starter torque limiter (=3-64)
STARTER MOTOR REMOVAL AND DISASSEMBLY • Remove the under cowling . (=6-5) 6-5) • Disconnect the starter motor lead wire 90 and remove the starter motor .
7-14 ELECTRICAL SYSTEM
• Disassemble the starter motor as shown in the illustration .
T 02 ©3
• O5
• 07
•
0-ring Housing Armature Washer 0-ring Starter motor case Starter brush holder assembly 0-ring
i
STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder . If any damages are found, replace the brush assembly with a new one .
COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut OA . If abnormal wear is found, replace the armature with a new one . If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth . If there is no undercut, scrape out the insulator 10 with a saw blade .
ARMATURE COIL INSPECTION Check for continuity between each segment, and between each segment and the armature shaft using the multi circuit tester . If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one . 09900-25008 : Multi circuit tester set i E 0 e
Tester knob indication : Continuity test ( •I )))
V
ELECTRICAL SYSTEM 7- 1 5
OIL SEAL INSPECTION Check the oil seal lip for damage or leakage . If any damage is found, replace the housing end .
J l
STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassembly . Pay attention to the following points : • Apply SUSUKI SUPER GREASE to the lip of the oil seal . 99000-25030 : SUZUKI SUPER GREASE "A" (USA) 99000-25010 : SUZUKI SUPER GREASE "A" (Others)
• Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft . 99000-25140 : SUZUKI MOLY PASTE
• Apply a small quantity of THREAD LOCK to the starter motor housing bolts . 99000-32050 : THREAD LOCK "1342"
• Apply SUZUKI SUPER GREASE to the O-ring . 99000-25030 : SUZUKI SUPER GREASE "A" (USA) 99000-25010 : SUZUKI SUPER GREASE "A" (Others)
• Tighten the starter motor lead wire nut to the specified torque .
19 Starter
motor lead wire nut : 5 N .m (0 .5 kgf-m, 3 .7 Ib-ft)
7-16 ELECTRICAL SYSTEM
STARTER RELAY INSPECTION • • • •
Remove the front seat . (F--r6-7) Disconnect the O battery lead wire from the battery . Disconnect the starter relay coupler 1O . Remove the starter relay cover 02 .
• Disconnect the starter motor lead wire (s and battery lead wire ® . • Remove the starter relay 05 .
Apply 12 V to ® and © terminals and check for continuity between the positive and negative terminals using the multi circuit tester . If the starter relay clicks and continuity is found, the relay is OK . 09900-25008 : Multi circuit tester set Tester knob indication : Continuity test ( •~ l)) CAUTION Do not apply a battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and damaged . Measure the relay coil resistance between the terminals using the multi circuit tester . If the resistance is not within the specified value, replace the starter relay with a new one . Starter relay resistance : 3 - 6 SZ ..
09900-25008 : Multi circuit tester set
~y Tester knob indication : Resistance (SZ)
ELECTRICAL SYSTEM 7- 1 7
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION
J
Check the interlock system for proper operation . If the interlock system does not operate properly, check each component for damage or abnormalities . If any abnormality is found, replace the component with a new one . SIDE-STAND SWITCH • Lift and support the fuel tank . (F-74-65) • Disconnect the side-stand switch coupler and measure the voltage between Green and Black/Yellow lead wires . 09900-25008 : Multi circuit tester set P71 i Tester knob indication : Diode test (-~W) Green (O+ Probe) ON (Side-stand up) OFF (Side-stand down)
Black/Yellow (O Probe) 0 .4 - 0 .6 V
1 .4 V and more (Tester's battery voltage)
NOTE: If the tester reads under 1 .4 V when the tester probes are not connected, replace its battery . Down
GEAR POSITION SWITCH • Lift and support the fuel tank . (r-74-65) • Disconnect the gear position switch coupler and check the continuity between Blue and Black with the transmission in "NEUTRAL" .
ON (Neutral)
Blue
Black
0
0
OFF (Expect neutral) CAUTION When disconnecting and connecting the gear position switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged .
7-18
ELECTRICAL SYSTEM
• Connect the gear position switch coupler to the wiring harness .
• Turn the ignition switch to "ON" position and side-stand to upright position . Measure the voltage between Pink and Black lead wires using the multi circuit tester when shifting the gearshift lever from low to top . Gear position switch voltage : 0 .6 V and more (* Low to top gear position) (Pink - Black) (* Except neutral position) 09900-25008 : Multi circuit tester set 09900-25009 : Needle pointed probe set
1711
Tester knob indication : Voltage (--)
TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, and the side-stand relay and diode .
• Remove the front seat . (=6-7) 6-7) • Remove the turn signal/side-stand relay .
SIDE-STAND RELAY INSPECTION First check the insulation between tester . Then apply 12 V to terminals
O OD
©) and check the continuity between
O
and
and ©
OD
and
terminals with the ( O+
to
(e .
O
and
O
to
If there is no
continuity, replace the turn signal/side-stand relay with a new one . .. 0 e
09900-25008 : Multi circuit tester set Tester knob indication : Continuity test ( •) )))
ELECTRICAL SYSTEM 7- 1 9
J
DIODE INSPECTION Measure the voltage between the terminals using the multi circuit tester . Refer to the following table . Unit : V Probe of tester to :
0 0 0 0 0 0-
©, ©
OO
More than 1 .4 V (Tester's battery voltage)
©, © 0 .4-0 .6
09900-25008 : Multi circuit tester set go Tester knob indication : Diode test (-W) NOTE: If the multi circuit tester reads under 1 .4 V when the tester probes are not connected, replace its battery .
iii ©
OO
7-20
ELECTRICAL SYSTEM
IGNITION SYSTEM Engine stop switch
0 ECM
b Power source circuit
Ignition coil
CKP sensor I
0 1 0
I I
Sidestand relay
Spark plug 0 Wave form arrangement circuit
Fuse
#1 Ignition switch
t 0 a0 0
CPU
#2 ° o 'ta Fuse
Wave form arrangement circuit
Battery
Cam position sensor Throttle position sensor
Engine coolant temp . sensor
Gear position switch
m
m
NOTE: The fuel cut-off circuit is incorporated in this ECM in order to prevent over-running of engine . When engine speed reaches 10 600 r/min, this circuit cuts off fuel at the fuel injector . CAUTION Under no load, the engine can run over 10 600 r/min, even if the fuel cut-off circuit is effective, and it may cause engine damage . Do not run the engine without load over 10 600 r/min at anytime .
TROUBLESHOOTING NOTE: Check that the transmission is in neutral and the engine stop switch is in the "RUN" position . Pull the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing . No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections . Is there connection in the ignition switch couplers? YES
Go to Step 2 .
NO
Poor connection of couplers
V
ELECTRICAL SYSTEM 7-2 1
Step 2 1) Measure the battery voltage between input lead wires (O/W and B/W) at the ECM with the ignition switch in the "ON" position . Is the voltage OK? YES
NO
Go to Step 3 . • Faulty ignition switch • Faulty turn signal/side-stand relay • Faulty engine stop switch • Broken wire harness or poor connection of related circuit couplers
Step 3 1) Measure the ignition coil primary peak voltage . ( f"77-22) NOTE: This inspection method is applicable only with the multi circuit tester and the peak volt adaptor . Is the peak voltage OK? YES
Go to Step 4 .
NO
Go to Step 5 .
Step 4 1) Inspect the spark plugs . (=2-6) 2-6) Are the spark plugs OK? YES NO
• Poor connection of the spark plug cap (-s) • Go to Step 5 . Faulty spark plug (-s)
Step 5 1) Inspect the ignition coils . (E177-23) Are the ignition coils OK? YES NO
Go to Step 6 . Faulty ignition coil (-s)
Step 6 1) Measure the crankshaft position sensor peak voltage and its resistance . NOTE: The crankshaft position sensor peak voltage inspection is applicable only with the mufti circuit tester and peak volt adaptor. Are the peak voltage and its resistance OK? YES NO
• Faulty ECM • Poor connection of ignition couplers Faulty crankshaft position sensor
7-22
ELECTRICAL SYSTEM
INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Lift and support the fuel tank . (l1_,,--4-65)
• Disconnect both of the spark plug caps . (f'72-6) • Connect new spark plugs to each spark plug cap and ground them . NOTE: Make sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition . CAUTION Avoid grounding the spark plugs and suppling the electrical shock to the cylinder head cover (magnesium parts) in order to prevent the magnesium material from damage . Measure the No . 1 and No . 2 ignition coils primary peak voltage in the following procedure .
• Connect the multi circuit tester with peak voltage adaptor as follows . No . 1 ignition coil : OO Probe : Black terminal
• Probe : Ground No . 2 ignition coil : OO Probe : White/Blue terminal
• Probe : Ground
r
NOTE: Do not disconnect the ignition coil primary wire coupler . ..
09900-25008 : Multi circuit tester set
CAUTION Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual .
• Shift the transmission into neutral . • Allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage . In
• Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage . Ignition coil primary peak voltage : 200 V and more Tester knob indication : Voltage (--)
A
WARNING
While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock .
• If the peak voltage is lower than the specified values, inspect the ignition coil . (F---r7-23)
ELECTRICAL SYSTEM 7- 2 3
J
IGNITION COIL RESISTANCE • Disconnect the spark plug caps . Measure the ignition coil resistance in both the primary and secondary windings . If the resistance is not within the standard range, replace the ignition coil with a new one .
1
(
Ignition coil resistance Primary : 2 .8 - 4 .2 S2 ((O terminal - S terminal) Secondary : 24 - 36 kL2 (Plug cap - O terminal) 09900-25008 : Multi circuit tester set Tester knob indication : Resistance (4)
CKP SENSOR PEAK VOLTAGE • Remove the front seat . (116-7) • Disconnect the ECM coupler . NOTE: Make sure that all of the couplers are connected properly and the battery used is in fully-charged condition . Measure the CKP sensor peak voltage in the following procedures .
• Connect the multi circuit tester with peak volt adaptor as follows . O Probe : Green/Blue lead wire 9 Probe : Green lead wire ..
09900-25008 : Multi circuit tester set
CAUTION Before using the multi circuit tester and peak volt adaptor, be sure to refer to the appropriate instruction manual .
7-2 4
ELECTRICAL SYSTEM
• Shift the transmission into neutral . • Allow the engine to crank for a few seconds, and then measure the CKP sensor peak voltage . • Repeat the above procedure a few times and measure the highest peak voltage . [
CKP sensor peak voltage : 5 .0 V and more
IrPli Tester knob indication : Voltage (-)
If the peak voltage is lower than the specified values, check the peak voltage at the CKP sensor lead wire coupler (Z.
• Disconnect the CKP sensor lead wire coupler and connect the multi circuit tester with the peak volt adaptor . • Probe : Green lead wire • Probe : Blue lead wire • Measure the CKP sensor peak voltage at the CKP sensor lead wire coupler in the same manner as on the ECM coupler . CKP sensor peak voltage : 5 .0 V and more ~,~ Tester knob indication : Voltage (-) If the peak voltage on the CKP sensor lead wire coupler is OK but on the ECM coupler is out of specification, the wire harness must be replaced . If both peak voltages are out of specification, the CKP sensor must be replaced and re-checked .
CKP SENSOR RESISTANCE Measure the resistance between the lead wires and ground . If the resistance is not specified value, the CKP sensor must be replaced . CKP sensor resistance : 130 - 240 Q (Green - Blue) W Q (Green - Ground) 09900-25008 : Multi circuit tester set Tester knob indication : Resistance (S2)
ELECTRICAL SYSTEM
COMBINATION
METER
J) Conbination meter cover (2 Conbination meter unit
REMOVAL • Remove the body cowling . (r--r6-6) • Remove the meter panel mounting bolts and disconnect the meter coupler 1T . CAUTION
• When disconnecting and connecting the combination meter coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged .
• Do not attempt to disassemble the combination meter unit .
7- 2 5
7-2 6
ELECTRICAL SYSTEM
PARTS NAME
10 Turn signal indicator light Neutral indicator light (3 Indicator light (Oil, Temp ., FI) • SELECT button • Clock • Coolant temperature/Fl display (7 Odo/Trip meter display • ADJUST button ~9 Fuel indicator light 1o High beam indicator light
(2
OPERATING PROCEDURE INITIAL DISPLAY When the ignition switch is turned to ON, the indicator light and come on, then ©9 goes out two seconds later .
O
NOTE : If the power supply is cut (e, g, when the battery is replaced) : * The speedometer, tripmeter and clock are displayed after the initial display appears . * Since the clock resets to "1 :00", it will need to be readjusted. CHANGE THE DISPLAY MODE With each press of the SELECT button, the display changes between odometer, tripmeter A and tripmeter B as shown . Odometer -nTripmeter A~~ Tripmeter B1-
1
A WARNING To avoid riding with only one hand, do not operate the buttons while riding . ODOMETER • Displays the total distance travelled TRIPMETER • Displays the distance travelled since the tripmeter was last reset NOTE: The tripmeters A and B can be used independently .
• Hold down the ADJUST button for two seconds to reset the tripmeter .
ELECTRICAL SYSTEM 7-27
CLOCK
• Displays the time (hours and minutes) on a 12-hour clock • Setting the time 10 Push the SELECT and ADJUST buttons simultaneously until the hour display starts blinking .
02 Adjust the hour display by pushing the ADJUST button . NOTE: When the ADJUST button is kept depressed for more than two seconds, the display progresses continuously .
03 Push the SELECT button . The setting that is blinking can be changed .
® Adjust the minute display by pushing the ADJUST button .
($ Push the SELECT button to finish setting time .
TACHOMETER • The tachometer pointer operates one time as shown below to reset tachometer pointer, when connecting the battery or tachometer coupler .
i
ADJ
7-28 ELECTRICAL SYSTEM
ENGINE COOLANT TEMPERATURE METER AND INDICATOR • Disconnect the engine coolant temperature sensor coupler . CAUTION When connecting and disconnecting the engine coolant temp . sensor lead wire coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged .
• Connect the variable resistor OO between the terminals . • Turn the ignition switch "ON" . • Check the LCD and LED operations when the resistance is adjusted to the specified values . Engine coolant temp . sensor Variable resister
Resistance AO Over 2 .45 kS Approx . 0 .811 kS2 Approx . 0 .1 kS2 0c (Jumper wire)
LED ©
LCD ©
OFF
---
OFF
"50"
-
Water temperature Under 19 °C Approx . 50 °C
ON
"120"-"139"
Flicker
120-139 0 C
ON
"HI"
Flicker
Over 140 °C
LCD 0
If either one or all indications are abnormal, replace the combination meter with a new one . NOTE: If the engine stop switch is turned OFF while the ignition switch is ON, the LCD displays "CHEC" . But it is not malfunction . This condition implies that combination meter receives no signal from the ECM. In that case, they are restored to ordinary indication by turning the engine stop switch RUN .
ELECTRICAL SYSTEM 7-29
1
FUEL LEVEL INDICATOR SWITCH INSPECTION 4-69) • Remove the fuel pump assembly . (=4-69)
• Connect 12 V battery and test bulb (12 V, 3 .4 W) to the fuel level indicator switch as shown in the right illustrations . The bulb should come on after several seconds if the switch is in good condition .
• When the switch is immersed in water under the above condition, the bulb should go out . If the bulb remains it, replace the unit with a new one .
FUEL LEVEL INDICATOR LIGHT INSPECTION If the fuel level indicator light does not function properly, check the fuel level indicator switch and its lead wire/coupler . If the fuel level indicator switch and its lead wire/coupler are all right, replace the combination meter with a new one .
OIL PRESSURE INDICATOR NOTE: Before inspecting the oil pressure switch, check the engine oil level . (rr 2-15)
• Remove the under cowling . (C 7-6-5) • Disconnect the oil pressure switch lead wire from the oil pressure switch .
• Turn the ignition switch "ON" position .
7 .30 ELECTRICAL SYSTEM
Check if the oil pressure indicator will light, when grounding the lead wire . If the oil pressure indicator does not function properly, replace the meter with a new one after checking the connection of couplers .
SPEEDOMETER If the speedometer, odometer or trip meter does not function properly, inspect the speedometer sensor and connection of coupler 1) . If the speedometer sensor and connection are all right, replace the meter with a new one .
SPEEDOMETER SENSOR • Disconnect speedometer sensor coupler . • Remove the speedometer sensor (2 by removing its mounting bolt .
• Connect 12 V battery, 10 kQ resistor and the multi circuit tester as shown in the right illustration . B/R : Black with Red tracer B/W : Black with White tracer B : Black :. 09900-25008 : Multi circuit tester set Tester knob indication : Voltage (=)
• Under above condition, if a suitable screwdriver touching the pick-up surface of the speedometer sensor is moved, the tester reading voltage changes (0 V - 12 V or 12 V - 0 V) . If the tester reading voltage does not change, replace the speedometer sensor with a new one . NOTE : The highest voltage reading in this test will be the same as that of battery voltage .
ELECTRICAL SYSTEM
LAMPS HEADLIGHT AND POSITION LIGHT
10 Head light 12 V 60/55 W x 2 (2 Position light 12 V 5 W x 2
BULB REPLACEMENT Headlight • Remove the headlight coupler and boot .
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• Unhook the holder spring 9I and replace the headlight bulb .
Position light • Open the lids . (L & R)
• Remove the position light couplers 10 . (L & R) CAUTION If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure .
7- 31
7-32
ELECTRICAL SYSTEM
HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam, both vertical and horizontal . • Turn the adjuster OA for the horizontal adjustment .
NOTE: To adjust the headlight beam, adjust the beam horizontally first, then adjust the vertically.
• Turn the bolt © for the vertical adjustment .
BRAKE LIGHT/TAILLIGHT, TURN SIGNAL LIGHT AND LICENCE PLATE LIGHT
ELECTRICAL SYSTEM 7- 3 3
RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode .
INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light . If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection . If the bulb, turn signal switch and circuit connection are OK, the turn signal relay may be faulty ; therefore, replace the turn signal/ side-stand relay with a new one . T) NOTE : * Make sure that the battery is fully charged . * Refer to page 7-17 for the side-stand relay and diode inspection .
SIDE-STAND RELAY TURN SIGNAL RELAY 4)
STARTER RELAY r-77-1 6 FUEL PUMP RELAY 17'4-69
7-34
ELECTRICAL SYSTEM
SWITCHES IGNITION SWITCH REMOVAL • Lift and support the fuel tank . (=4-65)
• Remove the air cleaner box . (F--74-75) • Disconnect the ignition switch coupler .
• Remove the body cowling . ( r-76-6) • Remove the ignition switch mounting bolts with the special tools . 09930-11920 : Torx bit JT40H 09930-11940 : Bit holder CAUTION When reusing the ignition switch bolt, clean thread and apply THREAD LOCK . 99000-32050 : THREAD LOCK "1342"
ELECTRICAL SYSTEM 7. 3 5
Inspect each switch for continuity with the multi circuit tester . If any abnormality is found, replace the respective switch assemblies with new ones . 09900-25008 : Multi circuit tester set IGNITION SWITCH Color R Position ON
ON
0
Br
P
J
DIMMER SWITCH Color W Position HI (=D) LO (D) 0
y
0
0
0 0
TURN SIGNAL SWITCH
Color Position L PUSH R
Lg
0
Lbl
B
0
0
J
0
O/W
O/W
PUSH
0
B
0
0
0
REAR BRAKE SWITCH Color O/G Position OFF ON 0
13/131
PUSH
0
W/B
0
B/Y
B/Y
ON
OIL PRESSURE SWITCH Color G/Y Position ON (engine O is stopped) OFF (engine is running)
Ground O
Before inspecting the oil pressure switch, check the Y/G
HORN BUTTON Color
0
CLUTCH LEVER POSITION SWITCH
engine oil level. (C72-15) WIRE COLOR
Position
B/BI
NOTE:
STARTER BUTTON Color Position
Lbl
FRONT BRAKE SWITCH Color B/R Position OFF ON 0
Y
PUSH ENGINE STOP SWICH Color O/B Position OFF (>Z) RUN (0) 0
Lg
Color Position OFF
0
PASSING LIGHT SWITCH Color Position
HAZARD Color Position ON OFF
B/W
B Br LbI Lg 0 R Y W
: Black : Brown : Light blue : Light green : Orange : Red : Yellow : White
B/BI B/W B/Y B/R G/Y O/B O/G O/W
: Black with Blue tracer : Black with White tracer : Black with Yellow tracer : Black with Red tracer : Green with Yellow tracer : Orange with Black tracer : Orange with Green tracer : Orange with White tracer ON :Orange with Yellow tracer W/B : White with Black tracer Y/G : Yellow with Green tracer
7-3 6
ELECTRICAL SYSTEM
BATTERY SPECIFICATIONS
• • • •
Type designation
FTX14-BS
Capacity
12 V, 43 .2 kC (12 Ah)/10 HR
Anode plates Separator (fiberglass plate) Cathode plates Upper cover breather
© Stopper • Filter
• Terminal • Safety valve
INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 10 sealing the battery electrolyte filler holes 02 .
• Remove the caps (T . NOTE : * After filling the electrolyte completely, use the removed caps O3 as the sealed caps of battery filler holes . * Do not remove or pierce the sealed areas ® of the electrolyte container .
• Insert the nozzles of the electrolyte container ($ into the battery's electrolyte filler holes, holding the container firmly so that it does not fall . Take precaution not to allow any of the fluid to spill .
IN
V
ELECTRICAL SYSTEM
• Make sure air bubbles © are coming up each electrolyte container, and leave in this position for about more than 20 minutes .
NOTE : If on air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times . Never remove the container from the battery .
• After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery . Wait for about more than 20 minutes .
• Insert the caps O7 into the filler holes, pressing in firmly so that
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the top of the caps do not protrude above the upper surface of the battery's top cover . CAUTION
• Never use anything except the specified battery . • Once install the caps to the battery ; do not remove the caps .
• Do not tap the caps with a hammer when installing them .
L)
oV
U
00 J°
Vo O
0
1
0
O
O°
I
H,I
Oo 0
U 0
U o
0 Go
0
G
0U
GV 0
Oo
~` oU
0G
7- 37
7-3 8
ELECTRICAL SYSTEM
• For initial charging, use the charger specially designed for MF battery . CAUTION
• For charging the battery, make sure to use the charger specially designed for MF battery . Otherwise, the battery may be overcharged resulting in shortened service life .
• Do not remove the cap during charging . • Position the battery with the cap facing upward during charging .
SERVICING Visually inspect the surface of the battery container . If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one . If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper .
RECHARGING OPERATION • Measure the battery voltage using the multi circuit tester . If the voltage reading is less than the 12 V (DC), recharge the battery with a battery charger . CAUTION When recharging the battery, remove the battery from
Charging period (V) 18 17 16 15 14 13 12
Stop charging
the motorcycle . 0
NOTE : While recharging, do not remove the caps on the top of the battery. Recharging time : 1 .4 A for 5 to 10 hours or 6 A for 1 hour CAUTION Be careful not to permit the charging current to exceed 6 A at any time .
• After recharging, wait at least 30 minutes and then measure the battery voltage using the multi circuit tester . If the battery voltage is less than 12 .5 V, recharge the battery again . If the battery voltage is still less than 12 .5 V after recharging, replace the battery with a new one .
• When a battery is left unused for a long time, its voltage needs to be regularly measured . When the motorcycle is not used for more than one month (especially during the winter season), measure the battery voltage at least once a month .
10
20 30 40 50 60 (Minutes) Time
